Beware of Behr blower motor resistors/FSUs

[indy525]

Hi all-

FSU went out on the 540, so I ordered a Behr branded FSU from autohausaz. Got to and unplugged the old unit without problems, went to plug to new one in the slot and couldn't get fully seat within the cutout.

Here's a pic of the cutout where the "rods" fit through:

20170624_161210.jpg

The problem is the Behr unit doesn't clear the screw next to the slot. The design is different as there is not enough clearance for that screw in the previous pic (in the picture I'm pointing to the area that is keeping the FSU from going all the way in the slot and clicking back in). See below:

20170624_161829.jpg

It appears that the FSU has been replaced possibly by a Velaro unit, unless velaro was OEM. Looks like the only option is to pony up the extra dough to get the BMW branded one. Hopefully Autohausaz will let me return it.

[bluptgm3]

Did you use you build date to look up part number in realoem.com? Perhaps the wrong part was ordered/shipped.
ECS Tuning can be a good source if you know your part number, as they often have photos of actual parts.

Valao is an OE supplier.
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[shwy]

I just replaced mine with a meyle branded part and it fit perfectly. Just FYI!

[JaxPlanet]

Installed Behr in 2015. No problems. It looks like you have the wrong part.

[indy525]

On autohausaz, there are two Behr models listed. One with an all metal housing (like the original) and the one with the plastic base. Researching, the one with the plastic base was chinese made and had a high failure rate, the metal housed one was german made. Obviously the all metal one is not made to fit, although the plug is the same.

Mine didn't come labeled, but ECS has the same one listed for my car:

https://www.ecstuning.com/b-genuine-...r/64118369561/

[dannyzabolotny]

I installed a Behr FSU into my 2000 540it (11/1999 build) and it worked out fine. Here's the comparison of what mine looked like:



The new one is on the left. It snapped into place with a very satisfying click and it cured all of my fan speed issues.

[JimLev]

The one above on the left that Danny posted is the redesigned FSU which was done maybe 5-6+ years ago.
The one on the right is a very OLD design that was subject to lots of failures.
I'm surprised the old style is still being sold.

[ViolinARC]

I installed a Behr FSU into my 2000 540it (11/1999 build) and it worked out fine. Here's the comparison of what mine looked like:



The new one is on the left. It snapped into place with a very satisfying click and it cured all of my fan speed issues.

+1...this was my experience on the '00. Fortunately I caught it "acting up" (draining my battery when parked) because it was doing it's thing when I was working on something else. I kept hearing the fan motor kicking in and upon further investigation, discovered that the FSU was UBER hot and cycling on/off constantly...

The one above on the left that Danny posted is the redesigned FSU which was done maybe 5-6+ years ago.
The one on the right is a very OLD design that was subject to lots of failures.
I'm surprised the old style is still being sold.

Gotta ditch the old stock somewhere...

[dannyzabolotny]

Yeah, you shouldn't be able to buy that old style anymore, unless they started making it again for some reason?


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[ViolinARC]

Just pulled and replaced the '03's FSU yesterday because the aux fan was running even though the a/c is off and the engine temp was fine. From my research,the FSU is the likely culprit. The original had already been replaced with a Behr Made in China ($40 version) and wasn't inserted properly either. The replacement is a Valeo Made in Germany ($127 version but I snatched it for $17.99 on FleaBay) from a BMW dealership and I was able to seat it properly. We shall see if it solves the aux fan issue...

[BMW540san]

Got 2 Valeos from RMeuropean in last few years. Each probably has 3+ years at least in service. No issues so far.

[RuskiE39]

This is a well known issue... mine didn't completely fit in place but till works perfectly as there is enough pressure on the unit from the surrounding enclosure to keep it seated.
The one I bought was a Hamburg-Technic brand.